Ultrasonic sanitation and disinfecting methods

ABSTRACT

A device for sanitizing and disinfecting a space includes a tank having an interior space for holding an aqueous sanitizing, disinfecting, and/or sterilizing liquid, a bottom sector, an air inlet sector, and an exhaust sector, inner walls of the exhaust sector and the air inlet sector forming a substantially “V”-shaped air pathway within the interior space. A liquid cascading reactor vessel is positioned within the bottom sector of the tank, a top edge of the reactor vessel in adjustably spaced relation from a notch in the “V”-shaped air pathway. A vibratable ultrasonic head array is positionable within and beneath a top edge of the reactor vessel and is submergable within the reactor vessel for vibrating the disc to form atomized micro-particles from the liquid. Air can be drawn into the air inlet, and the formed atomized micro-particles can be exhausted from the exhaust outlet.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of application Ser. No.11/624,317, filed Jan. 18, 2007, which is itself a continuation-in-partof application Ser. No. 11/277,176, filed Mar. 22, 2006.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to systems and methods for sanitizing anddisinfecting enclosed spaces, and, more particularly, to such systemsand methods that are capable of treating spaces three-dimensionally.

2. Description of Related Art

The sanitization and disinfection of enclosed spaces has become an issueof increasing importance owing to the possible presence of both naturaland deliberately introduced contaminants. Since most commercialbuildings are “sealed,” that is, their windows cannot be opened,circulation of “fresh” air is typically not possible within a particularroom. Similarly, most houses are now effectively sealed, with mostlyprocessed air being circulated. In addition, some forms of conveyance,especially airplanes, are of necessity sealed against the environmentduring flight.

The enclosed nature of modern spaces has led to such problems as “sickbuilding syndrome,” since molds and mildews can flourish in enclosed,damp environments, and also to the possibility of the natural ordeliberate introduction of more insidious threats to life, such asbiological and chemical agents. Some infectious agents, such ashepatitis virus and staph bacteria such as MRSA, are known to survive inareas such as hospitals and other healthcare facilities, and there, aswell as in other places such as cruise ships, schools, locker rooms, andcorrectional facilities, pose a health threat.

Another area of concern is the interior of vehicles, such as emergencyvehicles. Such vehicles can include ambulances, fire rescue units,police cars, and other EMS vehicles. In addition, other publicly usedvehicles such as buses, boats, subway cars, trains, and taxis can be ofconcern. These vehicles are seldom, if ever, cleaned to a levelsufficient to ensure the eradication of infectious agents.

At present most sanitizing and disinfecting agents are“two-dimensional,” that is, they are applied to accessible surfaces. Forexample, when disinfecting a table, typically the disinfectant isapplied to the table top, but not the underside.

“Fogging” agents are known for eradicating pests such as fleas and otherinsects. Ionization-type purifiers are also known in the art that useelectrostatic means to collect allergens and pollutants.

Therefore, it would be beneficial to provide a more effective device,system, and method for sanitizing and disinfecting enclosed spaces in athree-dimensional fashion.

SUMMARY OF THE INVENTION

The present invention provides a device for sanitizing and disinfectinga space. The device comprises a tank having an interior space forholding an aqueous sanitizing and disinfecting liquid, or,alternatively, a liquid sterilant. The words “sanitizing” and“disinfecting” are not intended as limitations, and one of skill in theart will recognize that the eradication of microbes can be referred toby a number of terms. A reactor vessel is supported within the interiorspace and above a bottom of the tank. Means are provided for maintaininga liquid depth in the tank interior space to a level beneath a top edgeof the reactor vessel. An ultrasonic head array comprising anultrasonically vibratable disc for generating ultrasonic energy ispositionable within and beneath the top edge of the reactor vessel,which also acts as a cascade tray, wherein the liquid level ismaintained substantially constant up to the top edge of the reactorvessel by causing spillage thereover. Means are included fortransferring liquid from the tank interior space to the reactor vesselto a level for substantially submerging the ultrasonic head array, and,as the reactor vessel comprises a cascade tray, to, and over, the topedge in a preferred embodiment, the cascading liquid then returned tothe tank interior space. Means are also provided for vibrating the discto form an atomized fog of particles from the aqueous sanitizing liquid.Further means are provided for exhausting the formed atomized fog fromthe reactor vessel to a space exterior of the tank.

It is important to note that the term “atomized fog” is intended to meanherein a virtually dry “mist” comprising micro-particles having justenough moisture to allow for adhesion of the particles to a surface,such as within an interior space, but to leave substantially no apparentresidue. Such a mist has been found to feel dry, and not wet. The dry“mist” fumigant created by the ultrasonic atomization process describedherein does not constitute a gas, but rather a mass of micro-particles,each believed to comprise a completely formulated micro-particle of adisinfectant solution without substantial thermal or solubilitydegradation owing to heat or high-pressure particle generation.

The device may also be used to distribute a liquid by creating theatomized fog as above and directing the fog to a desired location, forexample, for delivering fertilizer or pesticide to a plot of land, forwatering plants, or for distributing a skin-care product to the skin ofa user, although these uses are not intended to be limiting.

The device of the present invention is able to reach all areas in aspace where air can penetrate, and, since the atomized particles havebeen found to remain airborne longer than conventional mists, treatmentis more thorough, and less chemical is required to treat a surface areain a space than used by previously known atomization devices. A typicalroom of dimensions 12×12×10 ft can be disinfected and re-occupied in 20min or less, for example.

An alternate embodiment of the device of the present invention isconfigured for use in sanitizing the interior of a vehicle. Thisembodiment includes a hose having a proximal end affixable in fluidcommunication with the exhaust outlet. Means for sealing an at leastpartially open access area of a vehicle is provided, wherein the sealingmeans has an aperture in fluid communication with a distal end of thehose. This embodiment of the invention is useful for enabling asanitizing treatment of the vehicle's interior.

The features that characterize the invention, both as to organizationand method of operation, together with further objects and advantagesthereof, will be better understood from the following description usedin conjunction with the accompanying drawing. It is to be expresslyunderstood that the drawing is for the purpose of illustration anddescription and is not intended as a definition of the limits of theinvention. These and other objects attained, and advantages offered, bythe present invention will become more fully apparent as the descriptionthat now follows is read in conjunction with the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side cross-sectional view of an embodiment of the sanitizingdevice of the present invention.

FIG. 2 is a rear view of the device of FIG. 1.

FIG. 3 is an exploded perspective view of the reactor vessel of thedevice of FIG. 1.

FIG. 4 is a side view of the reactor tray.

FIG. 5 is a rear view of the reactor tray.

FIG. 6 is a top view of the reactor tray with ultrasonic head arrayspositioned therein.

FIG. 7 is a side-top perspective view of an ultrasonic reactor headarray, with one disk seen in exploded view.

FIG. 8 is an exploded view of a reactor head array disk.

FIG. 9 is a side perspective view of an alternate embodiment of anexhaust system including a diverter element.

FIG. 10 is a side cross-sectional view of an alternate embodimentincorporating a heating exhaust.

FIGS. 11A-11D are side cross-sectional views of different exemplaryembodiments of the reactor tray.

FIG. 12 is a schematic illustration of a side view of an alternateembodiment of the device.

FIG. 13 is a top/side perspective view of the inside of a reactor vesselfor the embodiment of FIG. 12.

FIG. 14 is a side cross-sectional view of an inner tank.

FIG. 15 is an exploded view of a particle filter.

FIGS. 16A,16B is a side perspective view of the mass blower operation.

FIG. 17 is a front view of the scrubbing device of the presentinvention.

FIG. 18 illustrates the spray nozzle connection.

FIG. 19 illustrates the use of a discharge hose to empty the tank offluid.

FIG. 20 is a side view of an embodiment of the sanitizing device.

FIG. 21 is a rear view of the device of FIG. 20.

FIG. 22 is a top/front view of the device of FIG. 20.

FIG. 23 is a rear view of the device of FIG. 20.

FIG. 24 is a top/front view of the device of FIG. 20.

FIG. 25 is a front perspective view of a device for sanitizing avehicle.

FIG. 26 is a side perspective view of the device of FIG. 25 in use.

FIG. 27 is a top/side perspective view of an alternate embodiment of areactor vessel and bracket assembly.

FIG. 28 is a side cutaway view of the device incorporating the reactorvessel bracket assembly of FIG. 27.

FIG. 29 is an exploded view of the level sensor.

FIG. 30 is a side cutaway view of the device of FIG. 28, illustratingthe position of the pump.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A description of the preferred embodiments of the present invention willnow be presented with reference to FIGS. 1-30.

The device 10 in a first embodiment for sanitizing and disinfecting aspace includes a tank 11 (FIGS. 1 and 2) that has an interior space 12for holding an aqueous sanitizing liquid 13. In a particular embodiment,the tank's top end 14 is substantially smaller than its bottom 15.Further, the tank 11 may be configured for placement upon a wheeled cart16 for ease of transport.

The tank 11 has a liquid line aperture 17 adjacent the top 14 and aliquid outlet 18 adjacent the bottom 15. The tank 11 can comprise amaterial adapted to maintain a static charge, such as, but not intendedto be limiting, a high-density polyethylene (HDPE) material.

A micro-particle outlet 19 is positioned adjacent the tank's top 14along the rear wall 20, and is in fluid communication with a chimney 21having a bore 22 therethrough leading to a space 23 exterior of the tank11. In a preferred embodiment, the chimney bore 22 has an elbow therein,shown by the dotted line in FIG. 1, meeting the fog outlet 19 at a firstend 24 and the exterior space 23 at the second, upwardly directed end25.

A reactor vessel 26 is supported within the tank's interior space 12 andabove the tank's bottom 15. In a particular embodiment illustrated inFIGS. 3-5, not intended to be limiting, the reactor vessel 26 comprisesa substantially hollow rectangular lower section 27 that has a pluralityof support legs 28 that extend from a bottom 29 thereof. An uppersubstantially rectangular section 30 comprises a bottom 31 and fourenclosing walls 32 that extending upwardly from the upper section'sbottom 31 and are adapted to contain liquid in the interior space 33formed thereby. The lower 27 and the upper 30 sections are affixabletogether with the upper section 30 atop the lower section 27 and arepositionable within the tank's interior space 12 with the support legs28 contacting the bottom surface 34 of the tank's interior space 12. Oneof skill in the art will recognize that additional embodiments for thereactor tray 26 could be envisioned, and that the shape presented herein is intended to be exemplary only.

In a particular embodiment, not intended to be limiting, the reactorvessel 26 is formed in two parts 27,30 in order to permit insertion intoa particular tank 11. Here the parts 27,30 are held together with theuse of joiner clips 35 that are screwed onto the lower section 27 andserve to brace the sections 27,30 together. The reactor vessel 26 hasone or more drain holes 36 or gravity-fed lines extending from theinterior space 33 of the reactor vessel 26 to the tank's interior space12 and is positioned adjacent the bottom 31 of the reactor vessel'sinterior space 33, or extends out of the reactor vessel's interior spaceby a hose to the tank's interior space 33.

The reactor vessel 26 further has affixed thereto a hose clamp 38 forsupporting a liquid line 39, which will be discussed in the following.The top surface 40 of the upper section 30 should preferably have anarea substantially greater than the top 14 of the tank 11.

Another feature of particular embodiments of the cascading reactorvessel 26 is that the top edge 41 of the upper section 30 can have aplurality of notches 42 therealong. These notches 42 can assist inpermitting liquid to pass therethrough, but to substantially preventfoam from passing therethrough, thus retaining foam within the uppersection 30 and not permitting it into the return line 39.

Positioned within the reactor vessel's upper section 30 is a pluralityof ultrasonic head arrays 43, here, three ultrasonic head arrays (FIGS.6-8). Each of the head arrays 43 comprises a plurality, here, nine,vibratable heads 44 for generating ultrasonic energy, operating in afrequency range of 1.30-2.5 MHZ, with a preferred value of 1.70 MHZ. Thehead arrays 43 are positioned so as to be submersible within the reactorvessel 26, the submersion depth 45 optimized for production of anatomized fog 46 of particles from the liquid 13 therewithin. Preferablythe fog 46 comprises negatively charged particles, which aid dispersaland space coverage. It has been found that the depth 45 of the liquidcolumn and also the vibration frequency affects the focus of the soundwaves. The signal for activating the discs 44 is transmitted fromdevices known in the art, such as by way of a manual switch or levelsensor.

The ultrasonic head arrays 43 can comprise head arrays such as can beobtained from Sonaer Ultrasonics (Farmingdale, N.Y.), although this isnot intended as a limitation. An exemplary head array that can be usedcomprises part number T241, although this is not intended to belimiting. The fog 46 created by these head arrays 43 can containparticles in a range of 0.25-5.0 μm, although this is not intended to belimiting, as the size may be larger or smaller in some instances. Eachof the discs 44 include a substantially toroidal O-ring seat 47, a VitonO-ring 48 seated on the O-ring seat 47, a ceramic disk 49 positionedatop the O-ring 48, and a substantially toroidal retaining ring 50positioned in circumferentially retaining relation atop the ceramic disk49. The discs 44 are known in the art to be supplied with siliconeO-rings, but it has been found that the increased stiffness and chemicalresistance of the Viton material is beneficial to the invention.

The drain hole 36 or drain hose discussed above has been found to bebeneficial in extending the life of the device 10 by keeping the headarrays 43 dry. A level sensor 51 can also be provided for automaticallyturning the head arrays 43 on and off depending upon the presence orabsence of liquid. The level sensor 51 can be positioned either on thetank 11 or on the head arrays 43 themselves.

Means are included for transferring liquid from the tank's interiorspace 12 to the reactor vessel 26 to a level for substantiallysubmerging the ultrasonic head array 43. For this purpose is provided aliquid line 39 that is in fluid communication with the tank's liquidoutlet 18 at an inlet end 53 and with the reactor vessel 26 at an outletend 54. The liquid line 39 in this embodiment passes through the liquidline aperture 17 between the inlet end 53 and the outlet end 54, and isaffixed to the reactor vessel 26 with the use of the hose clamp 38.

As illustrated with reference again to FIG. 1, a pump 55 is providedalong the liquid line 39 that is operable to move liquid 13 through theliquid line 39 from the tank's interior space 12 beneath the reactorvessel 26 to the interior space 33 of the reactor vessel 26. The liquid13 is pumped from the bottom 15 of the tank 11 through the liquid line39 via the clear portion 56 and into the tank through the liquid lineaperture 17 near the top end 14 of the tank. The liquid line outlet end54 delivers the liquid into the upper section 30 of the reactor vessel26 allowing the upper section 30 to be filled with the liquid 13 a andan overflow of liquid 13 b (illustrated with arrows) to continuouslycascade over the edge 41 into the bottom 15 of the tank 11 wherein theliquid 13 c is pumped through the liquid outlet as the liquid 13 dthrough the clear line portion 56 and to the liquid line aperture 17,and wherein the liquid 13 e is delivered to the upper section 30 torepeat the cycle from liquid 13 a. For one embodiment of the inventionas herein described by way of example, the liquid line 39 comprises asubstantially clear material, so that a portion 56 of the liquid line 39exterior of the tank 11 can thereby serve as an indicator of a liquidlevel within the tank's interior space 12 when the pump 55 is notoperating. The placement of the liquid line portion 56 outside the tank11 has also proven beneficial in assisting in cooling the liquid uponits pathway to the reactor vessel 26. In addition, a filtration elementmay be added to eliminate contaminants along the liquid line 39.

The device 10 further includes means for exhausting the atomized fog 46that is formed to an exterior of the tank 11. This can be accomplished,for example, with the use of a fan 57 positioned within the tank'sinterior space 12 above the reactor vessel 26 and positioned to directthe formed atomized fog 46 from a top surface 58 of liquid 13 in thereactor vessel 26 to the fog outlet 19.

An additional feature that may be provided in certain circumstancesincludes a means for heating the fog 46, which has been found to reducethe size of the fog particles. Such a heating means may comprise, forexample, a coil 59 (FIG. 10) positioned along the exhaust path.

It will be understood by one of skill in the art that many variations onthe embodiment discussed above may be contemplated. For example, theexhaust system may include a diverter element 60 as illustrated in FIG.9.

In addition, various alternate means may be employed to support theultrasonic head arrays 43, as shown in the flotation elements of FIGS.11A-11C, wherein a foam floater 61 (FIG. 11A), a sealed air cavity 62(FIG. 11B), or a floater ring 63 (FIG. 11C) may be used to support thetray 26 and the head arrays 43.

Further, the cascading reactor tray 26 may include a plurality ofcascading reactor vessels 26,26′26″ positioned adjacent each other, thetop edge 41 of a first reactor vessel 26 above the top edge 41′ of asecond reactor vessel 26′, and so on. In this embodiment the liquidtransferring means is adapted to transfer liquid 13 into the firstreactor vessel 26, thereby permitting a cascade of liquid from the firstreactor vessel 26 into the second reactor vessel 26′ and thence into thethird reactor vessel 26″ during operation.

The shape of the device as illustrated herein is not intended to belimiting. For example, in an alternate embodiment 10′ shown in FIG. 12,the tank 11′ may have a chimney 21′ at the rear of the tank, whichcomprises a liquid inlet as well as an outlet for the dry mist createdtherein, and an air intake 60 toward the front of the tank 11′.

Yet another embodiment 70 (FIGS. 13-24) comprises a reactor vesselhaving a smooth upper edge 75 on the lip 76, and two inlets 77 forfilling the vessel 74 (FIG. 13). A drain 78 permits emptying the vessel74.

The vessel 74 in this embodiment 70 is adapted to hold four ultrasonichead arrays 43 as described above within four reactor holders 79positioned in spaced relation within the vessel 74. Each reactor holder79 comprises an “X”-shaped element having upwardly extending clips 80 atthe end of each arm 81, the clips 80 positioned to surround theperiphery of each ultrasonic head array.

In this embodiment 70 the reaction holders 79 are affixed to the bottom82 of the reactor vessel 74, for example, via a glue such as epoxy,although this is not intended as a limitation. The holders 79 arebeneficial in elevating the reactor head arrays so that treatment fluidmay circulated under the reactor, helping to cool the head array. Theholders 79 also permit a secure fit and easy removal of the head arraysfor replacement or repair.

The cross-sectional view of FIG. 14 illustrates airflow (shown as doublearrows) for this embodiment 70. An inlet fan 83 at a front end of thetank 71 blows air toward the reactor vessel 74, and thence out theexhaust 84 at the rear end of the tank 71, carrying along with it theparticles created by the ultrasonic head arrays. The fluid level 85 isshown surrounding the vessel 74.

In a particular embodiment, as illustrated with continued reference toFIG. 14, the inlet fan 83 is mounted at an angle 86 a of approximately10 degrees to the horizontal. The shape of the tank 71 includes asubstantially “V”-shaped compression region 86 leaving a gap 87 betweenthe notch 88 of the “V”-shaped compression region 86 and the top 75 ofthe reactor vessel 74. As further illustrated, the air flow (double linearrows) is therefore moved from a high pressure area, designated bycircle H, to a low pressure area, designated by circle L. As is wellknown to those skilled in the art, and as described with Bernoulli'sPrincipal, the speed of the air flow will increase as a result of theair flow moving from a relatively higher pressure area to a relativelylower pressure area. The higher speed of the air flow thus moves thesmaller particles at a greater speed toward the exhaust 84, the largerand thus slower particles thus having a greater time to fall back towardthe vessel 74 under an influence of gravity. The compression region 86thus provides a culling out or filtering of smaller particles from theparticles generated at the top 75 of the vessel 74. It will beunderstood by one of skill in the art that the compression region 86 canalso be substantially “L”- or “J”-shaped, and can also be formed withthe use of deflectors or baffles to create a desired compression regionwithin or above the reaction zone above the vessel 74. Further, thecompression region 86 can be adjusted according to the size of the tank,the area of the cascade tray, the type and size of the reactor heads,the orientation of the air flow, and the tilt of the air flow fan inlet.It will also be understood by one of skill in the art that the means ofcreating air flow over the fluid can be exterior to the unit 70 from anoutside source.

This device 70 further comprises a particle filter 89 positioned withinthe chimney bore 90 (FIGS. 15 and 28). The particle filter 89 cancomprise a substantially inverted cone-shaped element, although this isnot intended as a limitation, and other shapes, such as “tear-drop”shape might also be contemplated. The particle filter 89 has asubstantially cylindrical support base 91 having an upper toroidal lip92 for supporting the filter 89 within the chimney bore 90 at theexhaust aperture 84. The filter 89 comprises a frame 290, which cancomprise metal or plastic, although these are not intended aslimitations. The frame 290 comprises a plurality of elongated ribs 291affixed at top ends 292 to the filter base 91, and meeting at bottomends 293 to define a small aperture 294, thereby forming a generallyconical shape, with windows 295 defined by the ribs 291.

Positioned in surrounding relation to the frame 290 is a conical firstfilter element 296, comprising in a particular embodiment a ¼-in.plastic mesh, having an aperture 297 at a bottom end 298. Positioned insurrounding relation to the first filter element 296 is a conical secondfilter element 299, comprising in a particular embodiment a meshcomprising, for example, nylon or plastic, and having an aperture 304 ata bottom end 305. The mesh comprises a first mesh 300 comprising a0.088-in. mesh and a second mesh 301 comprising a 0.05-in. mesh. Thesecond mesh 301 extends for an angle 303 approximately 80-85 degreesabout the second filter element 299, with the first mesh 300 extendingthe remaining 275-280 degrees. The second filter element 299 is orientedwithin the chimney bore 90 so that the second mesh 301 is in position toreceive fluid directly from the vessel 74, for deflecting largerparticles attempting to exit the device 150. Further, since the chimney350 also serves as the liquid inlet, the particle filter 89 acts toprevent debris from entering the chimney 350. A filter retaining clamp302 tightens atop the second filter element 299 to keep the first andsecond filter elements 296,299 in place atop the frame 290.

Thus, the particle filter 89 serves to prevent larger particles frombeing blown out the exhaust aperture 84, and fluid formed by filteredparticles runs back into the tank 71. When larger particles becomeaffixed to the particle filter 89, those particles themselves can alsoserve to form a filter medium. The particle filter 89 ensures thatparticles no greater than 5 μm are exhausted from the device 70, and aretypically in a range of 0.25-5 μm.

The filter 89 of the present invention is an important element. In aparticular embodiment, not intended as limiting, during an averagehourly treatment approximately 0.9 to 1.4 gallons of liquid disinfectantsolution is filtered back into the tank 71 for regeneration as a resultof the filter 89, assisting in ensuring that the output of the device isessentially a “dry mist.” Without the filter 89, the conversion ofapproximately 3.0 gallons an hour of solution creates a fog havingsignificantly more dampness therein. With the filter 89 in place,approximately 1.6-2.1 gallons per hour can be converted, although thisis not intended as a limitation.

The device 70 additionally comprises an outer shell 94 that encases theinner tank 71 of FIG. 14. The outer shell 94 comprises a mass blower 95for generating air flow toward the exhaust aperture 84 for acceleratingparticles exiting therefrom, and reducing coagulation thereof, spreadingthe particles out and thereby providing faster introduction of theparticles into the space to be treated (FIGS. 16A and 16B). The massblower 95 has a door 96 that is movable between a closed position (FIG.16A), wherein the particles exit substantially vertically, and an openposition (FIG. 16B) wherein the particles are blown away from the massblower door. Air flow generated via an inlet thus also creates a vacuumover the leading edge of the exhaust, helping to pull particles out ofthe chimney bore 90. When a fan for the mass blower 95 is turned on, theair pressure generated thereby opens the diverter door 96.

In yet another embodiment 150, believed at the time of filing torepresent a preferred embodiment, a reactor vessel 151 is provided thatis substantially rectangular (FIGS. 27, 28, and 30). Supported by twowalls 152 of the reactor vessel/cascade tray 151 are a plurality of,here, two, reactor cradles 153 each comprising a bottom support plate154 affixed to a tensor pinching clip 156 via bolts through outer holes325. The clip 156 comprises a substantially “U”-shaped element having aside 155 extending upward from an inwardly extending support shelf 323having holes 324 meeting the bottom support plate's holes 325. The clip156 further has a top 310 and outer portion 311 outwardly and downwardlyextending from each of the sides 155, respectively. It will beunderstood that the use of such clip portions 156 is not intended as alimitation, and that alternative affixing means could be contemplated,such as hooks, etc.

The clip portions 156 are dimensioned to rest atop the opposed reactorvessel walls 152. The suspension distance of the reactor cradles 153 canalso be adjusted, for example, with the use of one or more “shims,” suchas, but not intended to be limited to, a “U”-shaped spacer 320positionable between the clip's top 310 and reactor vessel wall 152, anupper spacer 321 positionable between the “U”-shaped spacer 320 and theclip's top 310, and a lower spacer 322 positionable between the bottomsupport plate 154 and the clip's support shelf 323, and having holes 326meeting holes 324,325. The adjustability of the reactor cradles 153 isfor achieving optimal reaction points with a plurality of liquidshaving, for example, different specific gravities and different chemicalformulations, including different surfactant formulations. The importantfeature is the ability to control and reproducibly set this suspensiondistance to achieve optimal conversion rates of liquid volume per time,since the reactor vessel 151 during operation is preferably kept in a“cascading” state, wherein there is no space between the walls' topedges 161 and the fluid level therein. This feature has been found toalmost double the conversion rate over previously used structures.

In a preferred embodiment, the reactor cradles 153 and reactor vessel151 are dimensioned so that their respective walls are closely opposed.Two reactor cradles 153 in this embodiment 150 are adapted for beingpositioned substantially parallel to each other, although thisparticular arrangement is not intended to be limiting.

It will be understood by one of skill in the art that the design choicesin the reactor vessel 151 and reactor cradles 153 can also includefeatures for adjusting configurations thereof. For example, the reactorcradles 153 can be adjusted in a horizontal plane to accommodatedifferent widths, heights, and configurations of the reactor vessel 151.

Each of the reactor cradles 153 can be affixed atop thereof two“X”-shaped reactor holders, substantially as described above forembodiment 70 (FIG. 13). Reactor heads 43 can then be positionedtherein, and retained in place with the use of a clamp 157 and bolt 158arrangement positioned between the reactors 43. This positioning permitsa precise placement of the reactor heads 43 relative to the reactorvessel 151, here, a distance 160 of 1.5 in. from the top edges 161 ofthe reactor vessel walls 152. The bottom faces 162 of the reactorcradles 153 are positioned in spaced relation from a bottom 163 of thereactor vessel 151, which has been found to enhance the cooling of thesolution therein, thereby prolonging the life of the reactors 43 bymaintaining them in a cooler state. This arrangement also facilitatesrepair and/or replacement of the reactors 43 and/or ultrasonic disks 44as needed, and further permits adjustment of the reaction focal pointvertically and horizontally under the air pressure zone of the apparatus150.

The reactor holders 157 are affixed in staggered relationship on each ofthe reactor cradles 153, as can be seen in the plan view of FIG. 28,permitting a closer packing of reactor heads 43 within the reactorvessel 151.

This embodiment 150 has been found to maximize micro-particle output bystabilizing and optimizing the ultrasonic reaction focal point in orabove the solution. Since the reactor heads 43 are secured to thereactor vessel 151, the possibility of misalignment and movement aresubstantially eliminated.

Further, in this embodiment 150 a pump 164, comprising a submersiblemagnetic centrifugal pump in a preferred embodiment, is used to transfersanitizing liquid to be atomized into the reactor vessel 151 via tubing165 (FIG. 30). The tubing 165 has a first end 166 in fluid communicationwith the pump 164 and a second end (not shown) positioned within thereactor vessel 151 adjacent the bottom 163 thereof, and is kept in thisposition with the use of a clamp 168, for example, a tensor pinchingclasp, to affix the tubing 165 to the top edge 161 of the reactor vessel151. This positioning permits continuous filling and overflowing of thereactor vessel 151 during pump operation, and further permits asiphoning out of liquid when the pump 164 is turned off, and requires noholes to be made in the reactor vessel 151.

Yet a further feature of the embodiments 70,150 is a micro-particleevacuation device 100 for scrubbing air in the treated space to removeany remaining particles, and also for creating an additional air currentwithin the space to assist particles to attach to surfaces within thespace (FIG. 17). This device 100 reduces the time required forreoccupation of the treated space, and is operated for a sufficient timeto scrub the air multiple times (e.g., six to eight or more), typicallyat a rate of 2500-3000 ft³/min. A deodorizer can also be added in theairflow of the scrubber 100 if desired.

The air scrubbing device 100 is connectable to the treatment device70,150, and uses 120 Vac in a particular embodiment, connected to asource of electricity separately from the treatment device 70,150. Thescrubbing device 100 can be operated via, for example, a touch screenpositioned on the treatment device 70,150, to which it can be connectedvia an “umbilical” line insertable into an input 167 (FIG. 21) on thedevice 70,150 for passing signals therebetween. The scrubbing device 100can also be operated independently of the treatment device 70, in a“manual” mode. The scrubbing device 100 comprises a pair of series ofair filters 102 positioned on a base 103 in opposed relation, eachleading to an inner space 104 from which filtered air is expelledthrough an exhaust 105. Each of the series of air filters 102 cancomprise, for example, a ¾-in. metal mesh 106 upstream of a 1¾HEPA-style filter 107, which in turn is upstream of a 4-in. mini-pleat(95%) filter 108. An indicator light 109 can also be provided that, at apredetermined vacuum load, illuminates when the filters 102 need to bechanged. A plurality of scrubbers 100 can also be connected in seriesand operated simultaneously if desired. Other elements may be added asdesired, such as, but not intended to be limited to, ultraviolet lights,needle-point ionizers, and/or ozone generators.

The “plumbing” aspect of the device 70 includes additional spray andfluid discharge features. The fluid, for example, can be administereddirectly (i.e., not in particulate form as generated by the ultrasonichead arrays) by way of a spray attachment 110 connectable to a hose 111in fluid communication with the inner tank 71 (FIGS. 14, 18, and 21).The spray attachment 110 can be connectable to the hose 111, forexample, a quick disconnect, and the hose 111 is retractable within theouter shell 94 adjacent an indentation 400 on one side thereof. Thequick disconnect has a safety foot valve that is operator controlled toprevent fluid discharge when disconnected.

Another hose, positioned on an opposite side from the administrationhose 111 in another indentation 401 can also be used to drain and emptythe tank 71 when the device 70 is not in use (FIG. 19). For thisoperation, a discharge hose sector 112 is connected to the hose 111, andthe sprayer pump is used to discharge fluid for storage into, forexample, a bottle 113 or other container.

The entire outer shell 94 and external components of this embodiment 70are depicted in FIGS. 20-24, although these details are not intended tobe limiting. The treatment exhaust 84 and mass blower 95 are positionedon the top 115 of the device 70, with the air inlets 116,117 to the massblower 95 and the inner tank 71 on the front 118 and slanted upper faces119, respectively. Handles 120 are provided, as well as wheels 121 forease of movement. A controller 122 is positioned on the rear 123 of thedevice 70, along with a touch screen 124, power cord 125, and plug 126.The drain attachment and hose can be on one side 128, and the sprayerhose 111 on the other side 129, although this configuration is notintended as a limitation.

An outline of the inner tank 71 is shown in FIG. 14, along with the airflows to the treatment blower 95 and into the inner tank 71.

Yet a further aspect of the present invention is directed to an elementfor detecting a level 85 (FIG. 14) of fluid remaining in the tank 71,which has been found to eliminate false readings that can be caused byenvironmental issues such as coagulation, condensation, and temperatureinversions. The sensor apparatus 180 (FIG. 29) in a particularembodiment comprises an enclosed element such as, but not intended to belimited to, a center tube 181. The tube 181 at a bottom end 182 has abottom opening 183 into which a floatation element 186 is inserted andretained therein with a bottom cap 185 and bottom rubber 184, retainedby cap 178. A liquid inlet hole 179, having a diameter, for example, of¼ in., is positioned on the bottom cap 185 of the sensor apparatus 180,the liquid inlet hole 179 for admitting surrounding liquid, the level ofwhich is desired to be sensed (FIG. 28). At a top end 187 of the centertube 181 is a coupler 188 surmounted by a top cap 189 into which isinserted a PVC ring 190, which supports a sensor holder 191. The sensorholder 191 in turn supports an ultrasonic sensor 192. An air ventilationhole is located adjacent the top end of the sensor apparatus adjacentthe top cap 189.

The sensor apparatus 180 is insertable into the tank fluid 193, a fluidlevel of which reflects that 85 in the tank 71. The flotation element,which may comprise, for example, a plastic disk 186, floats on the fluid193. The sensor apparatus 180 can be adjusted and oriented as desired.The sensor apparatus 180 can be supported within the tank 71 adjacentthe coupler 188 with the use of a plate 340 affixed within the tank 71having a hole 341 therethrough dimensioned for admitting the coupler 188(FIG. 28). A substantially inverted-“U”-shaped bracket 342 is affixed tothe plate 340 atop the hole 341. The bracket has a hole 343 that issmaller than the plate hole 341, and is dimensioned for admitting thering 190.

In use, the ultrasonic sensor 192 senses a distance between it and theplastic disk 186 and communicates the sensed data via a signal to aprocessor, which is in signal communication with a display forindicating the sensed fluid level 85.

Another aspect of the present invention is directed to a system 130 andmethod for sanitizing vehicle interiors (FIGS. 25 and 26). The systemincludes the device 70 as outlined above, and further comprises a hose131 having a proximal end 132 that is affixable in fluid communicationwith the exhaust outlet 84. The distal end 133 of the hose 131 isaffixable to an aperture 134 in a window seal element 135. In aparticular embodiment, the window seal element 135 comprises a flexible,substantially planar overlay 136 having a magnetic seal edge 137 aroundthe perimeter of the overlay 136. In a particular embodiment, theoverlay 136 can comprise a vinyl material, although this is not intendedas a limitation. Also in a particular embodiment, the hose 131 comprisesa serpentine, 6-in.-diameter hose that can extend between 6 and 12 feetto enable its use in virtually any size vehicle. A top retaining tab 138extends from a top edge 139 of the overlay 136, and the aperture 134 ispositioned centrally in the overlay 136. In some embodiments, the systemcan include one or more hose couplings to enable different hose lengthsto be used for different applications, for example, for vehicles, marinevessels, and aircraft.

In use, a window 140 of a vehicle 141 is at least partially rolled down,and the vehicle door 142 is opened. The top retaining tab 138 is placedover the top of the door 142, and the window seal element 135 drapesdown over the window 140. The door 142 is closed, and the magnetic sealedge 137 is pressed against the exterior of the door 142.

Next the hose 131 is attached to the fogging unit's exhaust 84, and theunit 70 is activated for a sufficient time to sanitize the vehicle'sinterior. Other types of interfaces, which could in some cases bepermanently installed, could also be contemplated for vehicles or marinevessels so that use of the unit 70 is facilitated.

Another important feature of the present invention includes the liquidcomposition used for sanitizing spaces, and a method of making thiscomposition. The invention is not intended to be limited, however, tothe precise composition and proportion of ingredients in the liquid.

In an embodiment, an additive that can be incorporated into the liquidto be atomized, depending upon the characteristics thereof, can be madeas follows: 40 gallons of clean, reverse-osmosis carbon-filtered wateris added to a clean plastic or stainless steel vessel, and a mixer isturned on. One pound of sodium metasilicate pentahydrate is mixed intothe water slowly, and mixing continues for 5 min. With the mixer stillrunning, a clean plastic vessel is used to remove 1 gal of mixedsolution for use in a pre-blending step. 70 ml of SE25 (Wacker ChemieAG, Munich, Germany), a silicone-based, food grade, antifoaming agent,is added to the pail, and mixed using a clean plastic rod until thesolution is blended thoroughly. At this point the solution appears to bea cloudy micro-emulsion. 60 ml of K-2 surfactant (Lonza ChemicalCorporation, Switzerland), used as a molecular coupler, is mixed slowlyinto the micro-emulsion until thoroughly blended.

With the mixer running, the pre-blend is added back into the firstvessel at a rate of 180 ml per min while the mixer is running, and themixer continues to run after the pre-blend has been added. Into a clean1000-ml beaker containing 700 ml reverse osmosis carbon-filtered water,2 oz of Palaklor-1103041 (Pylam Products Company, Inc., Tempe, Ariz.) isadded. This substance comprises a dye base for its ultravioletreflective traits and can be used as tracer. The Palaklor is notnecessary for the dry mist-optimizing aspect of the inventivecomposition, and can therefore be omitted if a tracer is not desired inthe mixture. The mixture is shaken for 1 min, and is then added to thefirst vessel with continued mixing.

Water is added to the first vessel to bring the volume up to 55 gal, andmixing continues for 15 min. When blending is complete, the mixturestands for 1 h prior to packaging. For use, the mixture is diluted 1:1with reverse osmosis carbon-filtered water.

To the mixture may be added sanitizing, disinfectant, and/or pesticidalelements such as, but not intended to be limited to,di-N-alkyl(C₈₋₁₀)-N,N-dimethylammonium chloride,N-alkyl(C₁₀₋₁₂)dimethylammonium chloride, tetrasodium ethylenediaminetetraacetate, sodium ethanol, 2-propanol, pyrethrum,octylphenoxypolyethoxyethanol (a nonionic surfactant), quaternaryammonia, formaldehyde, gluteraldehyde, hydrogen peroxide, chlorinedioxide, and electrolyzed brine known as Suprox A and B and ANK (PTA,Ltd., UK). The composition(s) that can be added can be chosen based uponcharacteristics of the constituents, such as the specific gravity andcomposition of the sanitizing, disinfecting, sterilizing, and/orpesticidal elements. The compositions of different solutions of themixture comprising the dry-mist optimizer may be preferable foroptimizing the dry mist; such elements may also be converted to dry mistwithout the mixture.

The composition when added to the disinfectant elements has been shownto kill pathogens of hepatitis B and C, staphylococcus aureus,streptococcus, avian influenza, methicillin-resistant staphlococcusaureus (MRSA), enterococcus bacteria, HIV, E. coli, pseudomonas,salmonella, listeria, Legionnaire's disease, human coronavirus, toxicmolds, fecal coliform, athlete's foot, and Clostridium difficile amongothers. Further, the composition when added to disinfectant elementsenables a reduced surface tension and reduced foaming.

Tests have been conducted with the device and composition of the presentinvention with disinfectant elements. Most of the particles produced bythe device were measured to be in a range of 0.3-0.5 μm. The kill ratesachieved with an intermediate-strength quaternary disinfectant aresimilar to those obtained by other systems known in the art that usehighly corrosive oxidizing sterilants, such as hydrogen peroxide gas. Itis believed, although not intended as a limitation, that the success isat least in part owing to the size of the particles produced by thesystem, which is not known to have been achieved heretofore.

In a particular case, for example, a test was conducted on 3.0 billionCFUs of sporing Clostridium difficile with a 20-minute treatment and20-minute dwell time. The treatment resulted in a 80% kill rate, anunexpected result, because the disinfectant used is not supposed to beable to kill this spore, and typically an oxidizing sterilant would berequired to kill this spore.

In the foregoing description, certain terms have been used for brevity,clarity, and understanding, but no unnecessary limitations are to beimplied therefrom beyond the requirements of the prior art, because suchwords are used for description purposes herein and are intended to bebroadly construed. Moreover, the embodiments of the apparatus andcomposition illustrated and described herein are by way of example, andthe scope of the invention is not limited to the exact details ofconstruction, constituents, and proportion.

Having now described the invention, the construction, the operation anduse of preferred embodiments thereof, and the advantageous new anduseful results obtained thereby, the new and useful constructions, andreasonable mechanical equivalents thereof obvious to those skilled inthe art, are set forth in the appended claims.

1. A method for sanitizing and disinfecting a space comprising: placingan aqueous sanitizing liquid into an interior space of a tank, the tankhaving a bottom sector, an exhaust sector having an inner wall, and anair inlet sector having an inner wall facing the exhaust sector innerwall, the air inlet sector inner wall and the exhaust sector inner wallforming a compression region for a air pathway within the interiorspace, and further having an air inlet in the air inlet sector and anexhaust outlet in the exhaust sector; continuously transferring aqueousliquid having at least one of sanitizing, disinfecting, and sterilizingproperties from the tank interior space to a reactor vessel positionedwithin the tank bottom sector; vibrating an ultrasonically vibratabledisc of an ultrasonic head array to generate ultrasonic energy, theultrasonic head array positioned within and beneath a top edge of thereactor vessel and submerged within the transferred liquid at asubstantially constant emersion depth resulting from the continuouslytransferring liquid step so as to form a plurality of atomizedmicro-particles therefrom; providing a preselected flow of air withinthe interior space from the inlet toward the outlet, the air flowingthrough the compression region from a high pressure to a low pressure,so as to cause smaller particles within the plurality of micro-particlesto move more quickly than larger particles thereof, the preselected flowof air allowing at least a portion of the larger micro-particles to fallback to the tank bottom sector and the plurality of micro-particlespreferentially enriched with the smaller micro-particles; providing amesh filter having a first cross sectional portion positioned forinitially receiving the preferentially enriched micro-particles and asecond cross sectional portion downstream therefrom, wherein the firstcross sectional portion is smaller than the second cross sectionalportion; passing the preferentially enriched micro-particles through themesh styled filter prior to exiting the exhaust outlet for a filteringthereof; and exhausting the preferentially enriched micro-particles fromthe reactor vessel through an exhaust outlet to a space exterior of thetank.
 2. The space-sanitizing and -disinfecting method recited in claim1, wherein the filtering step comprises using a particle filtercomprising a plurality of layers, the layers comprising a support framehaving apertures of a first size therethrough, a first filter elementpositioned in surrounding relation to the support frame and havingapertures of a second size therethrough, and a second filter elementpositioned in surrounding relation to the first filter element andhaving apertures of a third size therethrough, the first size greaterthan the second size, the second size greater than the third size. 3.The space-sanitizing and -disinfecting method recited in claim 2,wherein the first filter element comprises a 0.25-in. plastic mesh andthe second filter element comprises a 0.88-in. plastic mesh covering afirst portion of the first filter element and a 0.05-in. plastic meshcovering a second portion of the first filter element distinct from thefirst portion.
 4. The space-sanitizing and -disinfecting method recitedin claim 2, wherein the support frame, the first, and the second filterelement comprise substantially inverted conical-shaped elements.
 5. Thespace-sanitizing and -disinfecting method recited in claim 1, furthercomprising detecting a level of liquid in the tank.
 6. Thespace-sanitizing and -disinfecting method recited in claim 5, whereinthe detecting step comprises positioning a tube within the tank interiorspace, a flotation element movably positioned within the tube,permitting liquid to enter the tube, permitting a flotation element tofloat to a level representative of the liquid level in the tank, andcreating a signal based upon a distance between the flotation elementand a position above the liquid level.
 7. The space-sanitizing and-disinfecting method recited in claim 1, wherein the filter comprises aconical shape having an apex and a base thereof, and wherein the apex isupstream the base.
 8. A method for sanitizing and disinfecting a spacecomprising: placing an aqueous sanitizing liquid into an interior spaceof a tank, the tank having a bottom sector, an exhaust sector having aninner wall, and an air inlet sector having an inner wall facing theexhaust sector inner wall, the air inlet sector inner wall and theexhaust sector inner wall forming a compression region for a air pathwaywithin the interior space, and further having an air inlet in the airinlet sector and an exhaust outlet in the exhaust sector; continuouslytransferring aqueous liquid having at least one of sanitizing,disinfecting, and sterilizing properties from the tank interior space toa reactor vessel positioned within the tank bottom sector; providing anultrasonic head array having an ultrasonically vibratable disc;supporting the ultrasonic head array by a substantially “U”-shapedreactor cradle supported by the reactor vessel, each ultrasonic headarray comprising a plurality of vibratable disks affixed to a topsurface of the ultrasonic head array; vibrating an ultrasonicallyvibratable disc of an ultrasonic head array to generate ultrasonicenergy, the ultrasonic head array positioned within and beneath a topedge of the reactor vessel and submerged within the transferred liquidat a substantially constant emersion depth resulting from thecontinuously transferring liquid step so as to form a plurality ofatomized micro-particles therefrom; providing a preselected flow of airwithin the interior space from the inlet toward the outlet, the airflowing through the compression region from a high pressure to a lowpressure, so as to cause smaller particles within the plurality ofmicro-particles to move more quickly than larger particles thereof, thepreselected flow of air allowing at least a portion of the largermicro-particles to fall back to the tank bottom sector and the pluralityof micro-particles preferentially enriched with the smallermicro-particles; and exhausting the preferentially enrichedmicro-particles from the reactor vessel through an exhaust outlet to aspace exterior of the tank.
 9. The space-sanitizing and -disinfectingmethod recited in claim 8, wherein the reactor cradle comprises a pairof reactor cradles, each comprising means for supporting two head arraysand positionable in side-by-side relation to each other.
 10. Thespace-sanitizing and -disinfecting method recited in claim 8, furthercomprising adjusting a level of the reactor cradle relative to a levelof the liquid in the reactor vessel.
 11. A method for sanitizing anddisinfecting an environment comprising: placing an aqueous liquid havingat least one of sanitizing, disinfecting, and sterilizing propertiesinto an interior space of a housing; providing an air flow from an inletto an outlet of the housing; continuously transferring the aqueousliquid from the housing interior space to a reactor vessel positionedwithin the housing; operating an ultrasonic head positioned at apreselected fixed level below a surface of the aqueous liquid in thereactor vessel for forming a plurality of atomized particles to beemitted therefrom; compressing the air flow between the inlet and theoutlet for causing air to flow through from a high pressure to a lowpressure, thus causing smaller particles within the plurality ofatomized particles to move more quickly than larger particles therein,the air flow compressing allowing at least a portion of the largerparticles to fall away from the outlet and thus preferentially enrichthe plurality of atomized particles with the smaller atomized particles;directing the preferentially enriched atomized particles toward theoutlet; providing a mesh filter having a first cross sectional portionpositioned for initially receiving the preferentially enrichedmicro-particles and a second cross sectional portion downstreamtherefrom, wherein the first cross sectional portion is smaller than thesecond cross sectional portion; filtering the preferentially enrichedatomized particles by passing the particles through the mesh styledfilter prior to the exhausting; and exhausting the preferentiallyenriched atomized particles from the housing into a space outside thehousing.
 12. The method recited in claim 11, wherein the filteringcomprises separating the atomized particles into particles having afirst size and particles having a second size.
 13. The method recited inclaim 12, wherein the exhausting comprising exhausting only the firstsized particles into the outside space.
 14. The method recited in claim13, further comprising depositing the second sized particles into theaqueous liquid.
 15. The method recited in claim 13, wherein theexhausted atomized particles are sized to not exceed five microns. 16.The method recited in claim 11, wherein the ultrasonic head operating atthe preselected level below a surface of the aqueous liquid in thereactor vessel includes transferring the aqueous liquid from the housinginterior space into the reactor vessel to cause the aqueous liquidwithin the reactor vessel to cascade over an edge thereof formaintaining a constant immersion depth of the ultrasonic head within theaqueous liquid carried by the reactor vessel.